The noise in sensor data has a substantial impact on the reliability and accuracy of (ML) algorithms. A comprehensive framework is proposed to analyze the effects of diverse noise inputs in sensor data on the accuracy of ML models. Through extensive experimentation and evaluation, this research examines the resilience of a LightGBM ML model to ten different noise models, namely, Flicker, Impulse, Gaussian, Brown, Periodic, and others. A thorough analytical approach with various statistical metrics in a Monte Carlo simulation setting was followed. It was found that the Gaussian and Colored noise were detrimental when compared to Flicker and Brown, which are identified as safe noise categories. It was interesting to find a safe threshold limit of noise intensity for the case of Gaussian noise, which was missing in other noise types. This research work employed the use case of changeover detection in (CNC) manufacturing machines and the corresponding data from the publicly funded research project (OBerA).
7 April 2024 in Advances in Industrial and Manufacturing Engineering
Monitoring the metal Additive Manufacturing (AM) process is an important task within the scope of quality assurance. This article presents a method to gain insights into process quality by comparing the actual and target layers. Images of the powder bed were captured and segmented using an Xception–style neural network to predict the powder and part areas. The segmentation result of every layer is compared to the reference layer regarding the area, centroids, and normalized area difference of each part. To evaluate the method, a print job with three parts was chosen where one of them broke off and another one had thermal deformations. The calculated metrics are useful for detecting if a part is damaged or for identifying thermal distortions. The method introduced by this work can be used to monitor the metal AM process for quality assurance. Due to the limited camera resolutions and inconsistent lighting conditions, the approach has some limitations, which are discussed at the end.
The described data set contains features from the machine control of a five-axis milling machine. The features were recorded during thirteen series productions. Each series production includes a changeover process in which the machine was set up for the production of a different product. In addition to the timestamps and the twenty recorded features derived from Numerical Control (NC) variables, the data set also contains labels for the different production phases. For this purpose, up to 23 phases were assigned, which are based on a generalized milling process. The data set consists of thirteen .csv files, each representing a series production. The data set was recorded in a production company in the contract manufacturing sector for components with real series orders in ongoing industrial production.
In recent years, the use of indoor localization techniques has increased significantly in a large number of areas, including industry and healthcare, primarily for monitoring and tracking reasons. From the field of radio frequency technologies, an ultra-wideband (UWB) system offers comparatively high accuracy and is therefore suitable for use cases with high precision requirements in position determination, for example for localizing an employee when interacting with a machine tool on the shopfloor. Indoor positioning systems with radio signals are influenced by environmental obstacles. Although the influence of building structures like walls and furniture was already analysed in the literature before, the influence of metal machine tools was not yet evaluated concerning the accuracy of the position determination. Accordingly, the research question for this article is defined: To what extent is the positioning accuracy of the UWB system influenced by a metal machine tool?The accuracy was measured in a test setup, which consists of a total of four scenarios in a production environment. For this purpose, the visual contact between the transmitter and the receiver modules, including the influence of further interfering factors of a commercially available indoor positioning system, was improved step by step from scenario 1 to 4. A laser tracker was used as the reference measuring device. The data was analysed based on the type A evaluation of standard uncertainty according to the guide to the expression of uncertainty in measurement (GUM). It was possible to show an improvement in standard deviation from to with confidence level and thus provides conclusions about the setup of an indoor positioning system on the shopfloor.
While new production areas (greenfields) have state-of-the-art technologies for implementing digitalization, existing production areas (brownfields) and devices must first be upgraded with technologies before digitalization can be implemented. The aim of this research work is to use a case study to identify the differences in the implementation of machine learning (ML) projects in brownfields and greenfields. For this purpose, an ML application for the detection of changeover times on milling machines is implemented and analyzed in the brownfield and greenfield scenarios as well as a combined scenario. Particular attention is paid to the selection of sensors and features. It was found that the abundant availability of features in the greenfield scenario poses pitfalls when creating ML projects if the underlying sensors cannot be checked for their suitability. For the changeover detector use case, the best model quality was achieved for the combined scenario, followed by the greenfield scenario.